2002 ezgo will not move

[SuperdutyII]

I have a 2002 ezgo txt the batteries are fully charged and it will not move. There is a clicking noise on right side of cart. What is the best way to trouble shoot the controller and solenoid.

[JohnnieB]

First step is to identify which drive system your cart has, PDS or Series.

[SuperdutyII]

Series

[LukeL]

Check the solenoid first. Clicking doesn’t mean it’s working.

Use a multimeter on the large terminals and check for continuity when the pedal is pressed.

[scottyb]

If series it may have a precharge resistor between the big posts. If yes one will have to be removed for the continuity test.

[JohnnieB]

Connect your DVM's negative (black) test lead on the controller's B- terminal and the positive (red) test lead on the controller's M- terminal.

With Key = ON and F/R = F, press pedal just far enough to make solenoid click and you ought to read FULL battery pock voltage.

If you do, press pedal to floor and the voltage ought to decrease to zero.

If you don't get full battery pack voltage, use the attached schematic with high current circuit highlighted to trace the single current path back towards B+ at battery pack until you find the missing voltage.

[SuperdutyII]

when we pressed just enough to make solenoid click we had battery voltage but when we pushed pedal to floor it only dropped to about 24 to 26 volts never to zero.

[JohnnieB]

Originally Posted by SuperdutyII

when we pressed just enough to make solenoid click we had battery voltage but when we pushed pedal to floor it only dropped to about 24 to 26 volts never to zero.

Trace the gray cable out of the pedal box to the in-line connector.

Cut the molex plug and jack off, add four lengths of marine grade (adhesive filled) shrink tubing to the wires and reconnect them with butt-splices or solder joints, then shrink the tubing.


-----------
If that doesn't fix it, check the ITS voltages. See attached for specs.

[SuperdutyII]

on test 23 we checked the voltage on B- and pin2 and voltage was 14.4. the other 2 test where good. do you have a pic of where to cut wires and pic of pedal box. Thanks for helping

[JohnnieB]

Originally Posted by SuperdutyII

on test 23 we checked the voltage on B- and pin2 and voltage was 14.4. the other 2 test where good. do you have a pic of where to cut wires and pic of pedal box. Thanks for helping

The in-line connector is at the end of the gray (four wire) cable. Probably after is comes through frame into battery compartment. See attachment-1

Pedal box us under floor mat and is box shown at other end of cable in attachement-1. Innards of pedal box is shown in attachment-2.